Receiving jig

ABSTRACT

To separate resin molded parts that are used for a push button switch member with less light leakage from the side faces and less trouble in key operation, easily, a resin molded body comprises one or more resin molded parts for a push button switch member, a frame surrounding the outside of the resin molded parts, one or more gates connecting a plurality of the resin molded parts each other or the resin molded part to the frame and one or more runners crossing the longitudinal direction of the gates, wherein the gates are connected at the back faces of the resin molded parts not to be coated with light shielding paint, and wherein the runners are connected to the gates on the same surfaces as the resin molded parts are connected to and are connecting the opposing sides of the frame.

REFERENCE TO RELATED APPLICATIONS AND CLAIM OF PRIORITY

This is a division of U.S. application Ser. No. 11/853,512, filed Sep.11, 2007 now U.S. Pat. No. 7,586,056, which contains subject matterrelated to and claims the benefit of Japanese Patent Application No.2006-250850, filed in the Japanese Patent Office on Sep. 15, 2006, theentire contents of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present inventions relate to a resin molded body, its receiving jigand a method for manufacturing a push button switch member using theresin molded body and the receiving jig.

In a conventional method, a plurality of resin molded parts has beenmanufactured by processes comprised of: (i) a process for forming aresin molded body, wherein the resin molded body comprises a pluralityof resin molded parts connected at its side faces each other by gates(hereinafter called “side gates”); and (ii) a process for separating theresin molded parts from the side gates of the resin molded body.

For example, Japanese Patent Laid-Open Publication No. H08-183072discloses a resin molded body having runners, wherein the resin moldedparts and the runners are connected by the side gates of the parts. Theconventional method has been used for manufacturing a push button switchmember of a cellular phone and the like.

Recently, some of cellular phones have front parts with top faces whichare illuminated by a light source arranged at the back faces of thefront parts. The front parts are manufactured as following processes.First, a resin molded body having transparent resin molded parts for apush button switch member is produced. Then, the top faces and the sidefaces of the transparent resin molded parts are coated with lightshielding paint except for predetermined part of the top faces which aredesigned to be bright. Finally, the resin molded parts are separatedfrom the resin molded body.

Using the above method for manufacturing the front parts from the resinmolded body having the side gates, some region of the side faces of theresin molded parts are not painted with light shielding paint, becausethe places to where the side gates were connected were not painted withthe paint in the coating process. In case of using the front parts as apush button switch member, light leaks through the non-painted regionsfrom back side.

In order to meet the needs of size reduction of a cellular phone, aclearance between keys which are major front parts of the push buttonswitch members, is becoming extremely narrow. In case of using the frontparts manufactured from the resin molded body having the side gates, apart of the gates is remained and causes a trouble in key operation. Asa solution for the light leakage and for the trouble in key operation,resin molded parts would be manufactured from a resin molded body havinggates connected at back face of each resin molded part (hereinaftercalled “overlap gates”). The back faces of resin molded parts to wherethe overlap gates would be connected are not needed to be coated bylight shielding paint. By using the overlap gates, the light leakagefrom the non-coating regions of the side faces of the resin molded partswould not occur. In other respect, since the overlap gates remain onlyon the back faces of resin molded parts, the resin molded parts remainedon the back faces do not cause any troubles in case of operating closelyarranged keys.

However, an efficient method for separating the overlap gates and theresin molded parts have not been developed yet, and there is a need ofan easy method for separating resin molded parts from the resin moldedbody in a short time.

SUMMARY OF THE INVENTION

It is an object of the present invention to easily separate resin moldedparts which are used for a push button switch member with less lightleakage from the side faces and less trouble in key operation.

The present invention is a resin molded body having resin molded partsfor a push button switch member and a frame surrounding an outside ofthe resin molded parts. The resin molded body of the present inventioncomprises one or more gates connecting a plurality of the resin moldedparts each other or between the resin molded parts and the frame,wherein the gates are connected at the back faces of the resin moldedparts not to be painted with light shielding paint. The resin moldedbody of the present invention also comprises one or more runnerscrossing the longitudinal direction of the gates wherein the runners areconnected to the gates on the same faces where the resin molded partsare connected to and wherein the runners connect the opposing sides ofthe frame.

The runners provided in the resin molded body make it possible thatvibration applied to the resin molded body transmits to each gatethrough the runners, and that the resin molded parts are separated offin a short time.

The other embodiment of the present invention is the resin molded bodywherein at least either one of the thicknesses or the widths of therunners are smaller than either one of the gates, and wherein the widthsof the runners connecting to the gates are wider than the widths of therunners non-connecting to the gates.

Wider area connecting to the gates (hereinafter, called “connectingportions”) make the connecting strength of the gates to the runnersenhanced. In the resin molded body according to this embodiment of thepresent invention, a binding power between the gates and the runners isstronger than a binding power between the gates and the resin moldedparts. In the process for separating the resin molded parts from theresin molded body, the resin molded parts are preferentially separatedfrom the gates.

According to the other embodiment of the present invention, the runnersare designed to be gradually widened in curves from non-connectingportions to the connecting portions. Such a shape prevents vibrationapplied to the resin molded body from concentrating to the connectingportions. Since the connections between the gates and the runners aredurable, in the process of separating the resin molded parts from theresin molded body, the resin molded parts are preferentially separatedfrom the gates.

Still the other embodiment of the present invention comprises one ormore runners with the wide portions formed at non-connecting portionswhich connect between the gates. Thus structure makes the runnersstronger. In the process of separating the resin molded parts from theresin molded body, the runners have not been destroyed until the resinmolded parts are separated from the gates.

The other embodiment of the present invention comprises one or morerunners with wide portions formed at non-connecting portions whichconnect between the gates, wherein the wide portions are designed to begradually widened in curve. The shape of the wide portions makes theboundary portions between non-wide portions and wide portions of therunners stronger. In the process of separating the resin molded parts,the runners have not been destroyed until the resin molded parts areseparated from the gates. Therefore, the resin molded parts are easilyseparated from the gates.

The other embodiment of the invention comprises one or more thickportions connecting the runners to the gates, wherein the thick portionsare formed on the same side as the back faces of the resin molded parts.The thick portions formed between the gates and the runners make theportions connecting between the gates and the runners stronger. In theprocess of separating the resin molded parts, the gates and the runnersare not easily separated off, while the resin molded parts and the gatesare easily separated off.

Still the other embodiment of the present invention comprises areceiving jig which is used as a receiver in separating resin moldedparts for a push button switch member from the resin molded body byapplying vibration. The receiving jig comprises one or more projectingportions that may support at least one of the front sides of the ends ofthe gates, the front side of the runners and the front side of a frame.Hereinafter “the front side(s)” means the same side as the front face ofthe resin molded parts that is the front side of a push button switchmember (the resin molded part) when it is assembled into a cellularphone. A resin molded parts in a resin molded body which are supportedby the projecting portions are not connected to the receiving jig. Inthis embodiment of the present invention, some gates are connecting to aplurality of resin molded parts, other gates are connecting to both theresin molded parts and a frame at the back faces of the resin moldedparts that are not needed to be painted. Also, in this embodiment of thepresent invention, the runners are crossing the longitudinal directionof the gates, the runners are connected to the gates on the same faceswhere the resin molded parts are connected to, and the runners areconnecting to opposing sides of the frame. The receiving jig alsocomprises one or more concave portions that are formed inside of theprojecting portions and filled with one or more elastic bodies, whereinthe elastic bodies filled in the concave portions are able to support atleast one of the gates, the runners and the frame in setting a resinmolded body to the receiving jig.

The embodiment of the receiving jig supports at least one of thegate-ends, the runners and the frame of the resin molded body at itsprojecting portions, and does not contact to the resin molded parts.When vibration is applied to the resin molded body, the connectingportions between the gates and the resin molded parts are effectivelyvibrated. In an arrangement of a resin molded body in the receiving jig,one or more elastic bodies filled in the concave portions of thereceiving jig contact to at least one of the gates, the runners and aframe of the resin molded body. When vibration is applied to the resinmolded body arranged in the receiving jig, the vibration is transmittedto connecting portions between the gates and the resin molded partswhich are not contacted to the elastic bodies, where the vibration isabsorbed at the elastic bodies. As a result, the resin molded parts areeasily separated from the gates.

The other embodiment of the present invention comprises a receiving jigwhich is used as a receiver when resin molded parts for a push buttonswitch member are separated by applying vibration to a resin moldedbody, wherein the receiving jig comprises one or more elastic bodies onthe faces contacting to a resin molded body which may support at leastone of a plurality of the front sides of the ends of the gates, thefront sides of runners and the front side of a frame of a resin moldedbody. In this embodiment of the present invention, some gates areconnecting to a plurality of resin molded parts and other gates areconnecting to resin molded parts and the frame at the back faces of theresin molded parts that are not needed to be painted. Also, in thisembodiment of the present invention, the runners are crossing thelongitudinal direction of the gates. The runners are connecting to thegates on the same side where the resin molded parts are connected to,and are connecting to opposing sides of the frame.

According to the embodiment of a receiving jig, in case of arranging aresin molded body, the elastic bodies support at least one of thegate-ends, runners and a frame. Also, a resin molded parts do notcontact to the receiving jig. When vibration is applied to the resinmolded body arranged in the receiving jig, the vibration is transmittedto the connecting portions between the gates and a resin molded partswhich are not contacted to the elastic bodies, where the vibration isabsorbed to the elastic bodies. As a result, the resin molded parts areeasily separated from the gates.

Still the other embodiment of the present invention is a method formanufacturing a push button switch member using a receiving jig byseparating resin molded parts for the push button switch member from aresin molded body with vibration, wherein the method includes a processof arranging the resin molded body in the receiving jig and a process ofapplying vibration by using vibration generating means to the gates atthe same side as the back faces of the resin molded parts. The resinmolded body used in the above method comprises the gates connecting aplurality of resin molded parts, a plurality of gates connecting to theresin molded parts and a frame surrounding the resin molded parts,wherein the gates are connected at the back faces of the resin moldedparts where are not to be painted. The resin molded body used in theabove method also comprises runners crossing the longitudinal directionof the gates, connecting to the gates on the same side where the resinmolded parts are connected to, and connecting to opposing sides of theframe.

In the embodiment of the method of manufacturing a resin molded part,vibration is efficiently transmitted to the connecting portions betweenthe gates and the resin molded parts, and the back faces of the resinmolded parts are easily separated from the gates. This embodiment of themethod of manufacturing the resin molded parts improves workingefficiency, reduces the number of working processes, and thereby reducesmanufacturing costs. This embodiment preferably includes a coatingprocess of putting a coat at least on the resin molded parts and thegates and a cutting process of cutting in borders between the resinmolded parts and the gates from the coated surface of the borders. As aresult, burrs generated by the coating surface of the gates do notremain on the resin molded parts when the resin molded parts and thegates are separated off each other.

According to the present inventions, the resin molded parts are easilyseparated from the resin molded body in a short time. Not only lightleakage from the side faces of the resin molded parts but also anytroubles in key operation do not occur.

BRIEF DESCRIPTION OF THE DRAWINGS

The following detailed description, given by way of example and notintended to limit the present invention solely thereto, will best beappreciated in conjunction with the accompanying drawings, wherein likereference numerals denote like elements and parts, in which:

FIG. 1A shows a perspective view from the front side illustratingconfiguration of a resin molded body according to a first embodiment ofthe present invention.

FIG. 1B shows a perspective view from the back side illustratingconfiguration of a resin molded body according to a first embodiment ofthe present invention.

FIG. 2A shows an enlarged view of a portion surrounded by adashed-dotted line A in FIG. 1A.

FIG. 2B shows an enlarged view of a portion surrounded by adashed-dotted line B in FIG. 1B.

FIG. 3 shows a cross sectional view of a resin molded body according tothe first embodiment of the present invention along the line C-C in FIG.1A.

FIG. 4 shows a cross sectional view of a resin molded body according tothe first embodiment of the present invention along the line G-G line inFIG. 2B.

FIG. 5 shows a perspective view illustrating configuration of areceiving jig according to the first embodiment of the presentinvention.

FIG. 6 is a flow chart showing processes for manufacturing a push buttonswitch member according to the first embodiment of the presentinvention.

FIG. 7 shows an arranging process in the method for manufacturing thepush button switch member according to the first embodiment of thepresent invention.

FIG. 8 shows a perspective view of the resin molded body arranged on thereceiving jig.

FIG. 9 shows a cross sectional view of a resin molded body according tothe first embodiment of the present invention along the line D-D in FIG.8.

FIG. 10A shows a downward movement process in the method formanufacturing the push button switch member according to the firstembodiment of the present invention.

FIG. 10B shows a vibrating process in the method for manufacturing thepush button switch member according to the first embodiment of thepresent invention.

FIG. 10C shows a state that the resin molded parts are separating fromthe gates.

FIG. 11A shows a perspective view from the front side illustratingconfiguration of the resin molded body according to a second embodimentof the present invention.

FIG. 11B shows a perspective view from the back side illustratingconfiguration of the resin molded body according to a second embodimentof the present invention.

FIG. 12A shows an enlarged view of a portion surrounded by adashed-dotted line E in FIG. 11A.

FIG. 12B shows an enlarged view of a portion surrounded by adashed-dotted line F in FIG. 11B.

FIG. 13 shows a perspective view illustrating configuration of thereceiving jig according to the second embodiment of the presentinvention.

FIG. 14 is a view for explanation of the method for manufacturing thepush button switch member according to the second embodiment of thepresent invention and shows a cross sectional view of a resin moldedbody arranged on the receiving jig.

FIG. 15A shows a downward movement process in the method formanufacturing the push button switch member according to the secondembodiment of the present invention.

FIG. 15B shows a vibration process in the method for manufacturing thepush button switch member according to the second embodiment of thepresent invention.

FIG. 15C shows a state that the resin molded parts are separating fromthe gates.

FIG. 16A shows alternative examples of the resin molded body and thereceiving jig of the present invention and shows a cross sectional viewof the resin molded body arranged on the receiving jig.

FIG. 16B shows alternative examples of the resin molded body and thereceiving jig of the present invention and shows a cross sectional viewof the resin molded body arranged on the receiving jig.

FIG. 17 shows an enlarged view of an alternative example of a resinmolded body of the present invention.

FIG. 18 shows a perspective view of an alternative example of areceiving jig of the present invention, wherein the receiving jig hascircular concave portions and groove portions.

FIG. 19 shows alternative examples of a resin molded body and areceiving jig of the present invention, showing a cross sectional viewwherein the resin molded body having the projecting portions is arrangedon the receiving jig having the circular concave portions and the grooveportions.

FIG. 20 shows an alternative example of a resin molded body of thepresent invention, wherein reinforcing members are provided on runnersin the resin molded body according to the first embodiment of thepresent invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS First Embodiment ofthe Present Invention

Hereinafter, a first embodiment of the present invention will bedescribed with referent to the drawings.

FIG. 1A shows a perspective view from the front side illustratingconfiguration of the resin molded body 10 according to the firstembodiment. FIG. 1B shows a perspective view from the back faceillustrating configuration of the resin molded body 10 according to thefirst embodiment. FIG. 2A shows an enlarged view of a portion surroundedby a dashed-dotted line A in FIG. 1A. FIG. 2B shows an enlarged view ofa portion surrounded by a dashed-dotted line B in FIG. 1B. FIG. 3 showsa cross sectional view of the resin molded body 10 according to thefirst embodiment along the line C-C in FIG. 1A. FIG. 4 shows a crosssectional view of the resin molded body 10 according to the firstembodiment along the line G-G line in FIG. 2B.

As shown in FIGS. 1A and 1B, the resin molded body 10 comprises twelveresin molded parts 12 (hereinafter referred to as “a part 12” or “parts12”) for the push button switch member, a frame 14 surrounding anoutside of the parts 12, overlap gates 16 (hereinafter referred to as “agate 16” or “gates 16”) connecting to back faces of the parts 12(hereinafter referred to as “a back face 12 b” or “back faces 12 b”) orconnecting to the back faces 12 b and the frame 14, and runners 18connecting to the plurality of gates 16 and connecting to the opposingsides of the frame 14.

The resin molded body 10 is formed by integral molding of a resinmaterial. The material forming the resin molded body 10 includespolyethylene (PE), polypropylene (PP), polybutylene (PB), polyvinylidenechloride (PVDC), chlorinated polyvinyl chloride (PVC-C), polystyrene(PS), polycarbonate (PC), styrene/acrylonitrile resin (SAN),acrylonitrile/butadiene/styrene resin (ABS) and the like, but is notlimited to the above materials.

As shown in FIGS. 1A and 1B, the parts 12 are arranged inside of theframe 14 in four rows and three columns with specified intervals. Eachpart 12 has a rectangular flat-plate shape. On a front surface 12 a anda forward side surface 12 c, a rearward side surface 12 c, a left sidesurface 12 c and a right side surface 12 c (hereinafter collectivelyreferred to as “a side surface 12 c”) of the part 12, a coated layer 12d is formed by applying paint. On the front surface 12 a of the part 12,numbers from “0” to “9” and symbols of “*” and “#” are formed by etchingor the like. The parts 12 adjacent to a forward-and-rearward directionare connected by the gates 16. Six parts 12 arranged at the most forwardrow and the most rearward row are connected to the frame 14 by the gates16. Each gate 16 is connected substantially to the center in theright-and-left direction of the part 12.

As shown in FIGS. 2A, 2B and 3, the gate 16 has a substantiallyrectangular shape. There is no limitation for the size of the gate 16.As shown in FIG. 3, at the both forward-and-rearward direction ends 20of a front surface 16 a of the gate 16, the gate 16 is connecting to thepart 12 at the outer edge of the back surface 12 b of the part 12. Anoverlap indication H that corresponds to the length of this connectingportion in the forward-and-rearward direction is not limited butpreferably a value in a range from 0.15 to 0.30 mm.

As shown in FIGS. 1A and 1B, the frame 14 is a square frame with asquare shaped cross-section. At vicinity of each of four corners in theframe 14, a projection 22 is provided toward downside. At a forwardframe portion 14 a and a rearward frame portion 14 b of the frame 14, aflat-plate portion 23 a and a flat-plate portion 23 b are extendedtoward forward and rearward, respectively. Three parts 12 arranged atthe most forward position and the forward frame portion 14 a areconnected by the gates 16. The gates 16 and the forward frame portion 14a are connected in a manner that the front surface 16 a of the gate 16is contacting to a back face 14 c of the forward frame portion 14 a.Also, three parts 12 arranged at the most rearward position and therearward frame portion 14 b are connected by the gates 16. The gates 16and the rearward frame portion 14 b are connected in a manner that thefront faces 16 a of the gates 16 are contacting to a back face 14 d ofthe rearward frame portion 14 b.

As shown in FIGS. 1A and 1B, between the parts 12 adjacent to theforward-and-rearward direction, runners 18 connecting a left frameportion 14 e and a right frame portion 14 f each other are providedalong the right-and-left direction. The runner 18 is gradually widenedtoward a connecting portion 19 of the runner 18 where the runner 18 isconnected to the left frame portion 14 e and toward a connecting portion19 of the runner 18 where the runner 18 is connected to the right frameportion 14 f. A juncture portion of the runner 18 is formed between theconnecting portion 19 and a non-connecting portion 26, wherein thenon-connecting portion 26 is a portion of the runner 18 where the runner18 is not connected to the gate 16 or to the frame 14 and where therunner 18 has the same width. The juncture portion has a curve shapewith a value of a curvature radius R in a range from 0.5 to 1.0 mm (R0.5to R1.0).

As shown in FIG. 2A, the runners 18 cross the gates 16 provided alongthe forward-and-rearward direction and are connected to the front faces16 a of the gates 16 at the connecting portions 25. The connectingportions 25 are wider in the forward-and-rearward direction than thenon-connecting portions 26. At juncture portions 28 of the runners 18placed between the connecting portions 25 and the non-connectingportions 26, curve portions 29 where the runners 18 are graduallywidened from the non-connecting portions 26 toward the connectingportions 25 are formed. A value of a curvature radius R of the curveportions 29 is preferably but not limited to in a range from 2.0 to 4.0mm (R2 to R4).

At the substantially central position between the connecting portions 25of the runner 18, a wide portion 30 is formed, wherein the wide portion30 is wider in the forward-and-rearward direction than thenon-connecting portion 26. The runner 18 is gradually widened from thenon-connecting portion 26 to the wide portion 30. Between the wideportion 30 and a narrow width portion 32 that is the portion of therunner 18 where the runner 18 starts to widen from the non-connectingportion 26 to the wide portion 30, the runner 18 has a boundary portion34. At the boundary portion 34 of the runner 18, a curve portion 36 isformed. At the curve portion 36, the runner 18 is gradually widened fromthe narrow width portion 32 to the wide portion 30. A value of acurvature radius R of the curve portion 36 is preferably but not limitedto in a range from 2.0 to 4.0 mm (R2 to R4).

As shown in FIG. 2B, on the back face of the runner 18 between theconnecting portion 25 and the non-connecting portion 26, a thick portion38 is provided, wherein the thick portion 38 is thickened in front toback direction gradually from the non-connecting portion 26 toward theconnecting portion 25. As shown in FIG. 4, the thick portion 38comprises a flat incline portion 38 a having a flat inclined face and acurve portion 38 b having a curve inclined face which is continued fromthe flat incline portion 38 a. The flat incline portion 38 a is providedto incline backward from the back face of the runner 18 toward the gate16. A value of a width K that is the width of the flat incline portion38 a in the right-and-left direction is preferably but not limited to ina range from 1.3 to 1.6 mm. A value of a height L that is the height ofthe flat incline portion 38 a in the front-and-back direction ispreferably but not limited to in a range from 0.2 to 0.4 mm. The curveportion 38 b is provided from the flat incline portion 38 a to the gate16. A value of a curvature radius R of the curve portion 38 b ispreferably but not limited to in a range from 0.1 to 0.5 mm. The resinmolded body 10 is formed by injection molding. A cycle of the injectionmolding differs depending on the molding condition and on the length inthe forward-and-backward direction of a portion where the part 12 andthe gate 16 are overlapped (herein after referred to as “overlapamount”). In the case of the injection molding under overlap amount of0.3 mm and a tool temperature of 80° C., for example, the cycle of theinjection molding is approximately 8.5 seconds.

In the case of separating the parts 12 for a push button switch memberfrom the resin molded body 10, a method for applying vibration betweenthe part 12 and the gates 16 are preferably employed. In this method, areceiving jig 40 is used to support the resin molded body 10. Aconstruction of the receiving jig 40 will be described as follows.

FIG. 5 shows a perspective view illustrating configuration of thereceiving jig 40 according to the first embodiment.

The receiving jig 40 is used as a receiver in separating the part 12from a resin molded body 10. The receiving jig 40 mainly made from metalsuch as but not limited to aluminum or stainless steel.

As shown in FIG. 5, the receiving jig 40 has a cavity 42. A shape of thecavity 42 is in relation to a shape of a resin molded body 10 so thatthe resin molded body 10 fits into the cavity 42. In another word, thecavity 42 of the receiving jig 40 comprises concave portions atlocations corresponding to a part 12, a frame 14, the gates 16 and therunners 18 of the resin molded body 10.

As shown in FIG. 5, the cavity 42 comprises part fitting concaveportions 44, a frame fitting concave portion 46, gate fitting concaveportions 48 and runner fitting concave portions 50 corresponding to theparts 12, the frame 14, the gates 16 and the runners 18 of the resinmolded body 10, respectively.

The part fitting concave portions 44 are provided in four rows and threecolumns with specified intervals. The part fitting concave portion 44has substantially same shape as the shape of the part 12. The framefitting concave portion 46 is provided in a square frame shapesurrounding the outside of the part fitting concave portions 44. Therunner fitting concave portions 50 are provided along the right-and-leftdirection between adjacent part fitting concave portions 44. The gatefitting concave portions 48 are provided to articulate part fittingconcave portions 44 each other in the forward-and-rearward direction.The gate fitting concave portions 48 are provided to articulate the sixpart fitting concave portions 44 placed at the most forward and mostrearward position with the frame fitting concave portion 46.

Consequently, at right and left sides of the part fitting concaveportion 44 located at the central column in the right-and-left directionin the cavity 42, substantially I-shaped walls 52 (herein after called“I-shaped walls 52”) are provided. At left side of the part fittingconcave portions 44 located at the left column, substantially leftbracket shaped walls 53 (hereinafter called “the left bracket shapedwalls 53”) are provided, while at the right side of the part fittingconcave portion 44 located at the right column, substantially rightbracket shaped walls 55 (hereinafter called “the right bracket shapedwalls 55”) is provided. At substantially center position inright-and-left direction of the forward end of the I-shaped wall 52, anindentation from forward side to rearward side is provided at an indentportion 57. At substantially center position in right-and-left directionof the rearward end of the I-shaped wall 52, an indentation fromrearward side to forward side is provided at an indent portion 57.Outside of the frame fitting concave portion 46, an outer wall 59 isprovided. At the center position in right-and-left direction, theforward side and rearward side of the outer wall 59 have indentedportions toward forward and toward rearward, respectively (hereinaftercalled “projecting concave portions 60”). The I-shaped wall 52, theright bracket shaped wall 53, the left bracket shaped wall 55 and theouter wall 59 are same height in front-and-back direction.

On the gate fitting concave portions 48 and the runner fitting concaveportions 50, an elastic body 62 and an elastic body 64 are arranged,respectively. The elastic body 62 and the elastic body 64 may be madefrom but not limited to a resin such as silicone rubber. The elasticbody 62 and the elastic body 64 are lower in front-and-back directionthan the I-shaped wall 52, the right bracket shaped wall 53, the leftbracket shaped wall 55 and the outer wall 59.

Next, a method for manufacturing the resin molded body 10 and a methodfor manufacturing a push button switch member comprising a process ofseparating parts 12 for the push button switch member from the resinmolded body 10 by applying vibration and by using the receiving jig 40will be described referring to the drawings.

FIG. 6 shows a flow chart showing processes for manufacturing a pushbutton switch member according to the first embodiment. FIG. 7 shows anarranging process in the method for manufacturing the push button switchmember according to the first embodiment. FIG. 8 shows a perspectiveview of the resin molded body 10 arranged on the receiving jig 40. FIG.9 shows a cross sectional view of the resin molded body 10 according tothe first embodiment along the line D-D in FIG. 8. FIG. 10A shows adownward movement process in the method for manufacturing the pushbutton switch member according to the first embodiment. FIG. 10B shows avibrating process in the method for manufacturing the push button switchmember according to the first embodiment. FIG. 10C shows a state thatthe resin molded part 12 is separating from the gate 16.

First, the method for manufacturing the resin molded body 10 will bedescribed.

A resin molded body 10 is formed by an injection-molding with fillingresin such as polycarbonate into a molding die which has cavitiescorresponding to the parts 12, the frame 14 and the gates 16 (resinmolding process: S101). The resin used in the resin molding process isnot limited to polycarbonate but preferably polyethylene (PE),polypropylene (PP), polybutylene (PB), polyvinylidene chloride (PVDC),chlorinated polyvinyl chloride (PVC-C), polystyrene (PS),styrene/acrylonitrile resin (SAN), acrylonitrile/butadiene/styrene resin(ABS) or the like.

Secondly, the front face and the side faces of the resin molded body 10are coated by predetermined paint to form the coating layer 12 d(coating process: S102). In this coating process, a plurality of paintshaving different colors may be over-painted. Alternatively, laser beammay be applied to the coating layer 12 d, and then a transparentovercoat may be applied as a protective layer. In the case that thesurface is needed to be protected by a metal layer, a deposition may beapplied. The deposition belongs to “coating”. Then, some parts of thecoating layer 12 d on the parts 12 are removed by etching or the like toform characters, symbols or patterns (character forming process: S103).These characters, symbols or patterns are formed by etching, but may beformed by any methods. The resin molded body 10 is formed through theabove processes.

Next, a method for manufacturing a push button switch member will bedescribed.

As shown in FIG. 7, the resin molded body 10 is arranged on thereceiving jig 40 with the back face being upside (arranging process:S104). As shown in FIGS. 8 and 9, when the resin molded body 10 isarranged on the receiving jig 40, the gates 16 protrudes from thereceiving jig 40. As shown in FIG. 9, when the resin molded body 10 isarranged on the receiving jig 40, the front faces of the connectingportions 25 of the runners 18 are in contact with the upper faces 62 aof the elastic bodies 62, while the front faces of the parts 12 of theresin molded body are not in contact with the front faces 42 a of thecavity 42. As described above, the resin molded body 10 is supported atthe gates 16 by the elastic bodies 62 and the elastic bodies 64 of thereceiving jig 40.

Then, as shown in FIG. 10A, a horn 68 of an ultrasonic vibrator isbrought down from the upside (the back side) of the resin molded body 10arranged on the receiving jig 40 (downward movement process: S105). Atthe end of the horn 68, a plurality of projections 69 are providedcorresponding to the positions of the gates 16. As the horn 68 isbrought down, an end face 69 a of each projection 69 contacts to theback face 16 b of the gate 16. Then, the horn 68 is pressed onto thegate 16. At the time, the connecting portion 25 is slightly pushed intothe elastic body 62 (the pushed-in state is not shown in any figures).Then, as shown in FIG. 10B, ultrasonic vibration is applied (vibratingprocess: S106). Then, as shown in FIG. 10C, by an impact of theultrasonic vibration applied to the gates 16 and by heat generated fromthe impact, the parts 12 are separated from the gates 16. The separatedparts 12 are grasped by a machine or a person and aligned at apredetermined position in a predetermined assembling jig (aligningprocess: S107). The elastic body 62 and the elastic body 64 prevent theother portions in the resin molded body 10 from receiving a large impactand thereby being destroyed. The number of frequencies of the ultrasonicvibration applied to the gate 16 is preferably in a range from 10 to 40kHz. Further preferable number of frequencies of the ultrasonicvibration is in a range from 15 to 30 kHz. Contacting the end face 69 aof each projection 69 on the gates 16 preferably continues in a range0.1 to 1.0 sec. Further preferable time is about 0.5 sec. Thepeak-to-peak amplitude of vibration of the horn 68 is preferably in arange from 40 to 80 μm in up-and-down direction. Further preferablepeak-to-peak amplitude is about 60 μm. In addition, it is preferable toperform a cutting process in which cut surfaces on borders between theparts 12 and the gates 16 prior to the arranging process S104. Thecutting process enables the parts 12 and the gates 16 to be clearlyseparated off each other. As a result, it is possible to prevent theburrs made of the coating material from remaining on the resin moldedparts when the resin molded parts and the gates are separated off eachother. The depth of cutting is preferably from coated surfaces to theinsides of the gates 16, in particular, in a range from 0.1 to 0.3 mmfrom the surfaces of the gates 16. The cutting is preferably given byusing a molding tool, blade or the like.

Since the resin molded body 10 formed by the above method has a runner18 and vibration applied to the resin molded body 10 is transmitted toeach gate 16 through the runners 18, the parts 12 are separated in ashort time. Additionally, since the connecting portion 25 is wider thanthe non-connecting portion 26, the connecting strength between the gate16 and the runner 18 is enhanced, and the gates 16 and the parts 12 areeasily separated off.

The resin molded body 10 has curve portions 29 at the juncture portions28 of the runners 18 between the non-connecting portions 26 and theconnecting portions 25, wherein the curve portions 29 are graduallywidened from the non-connecting portions 26 to the connecting portions25. Thus structure prevents the vibration applied to the resin moldedbody 10 from concentrating to the juncture portions 28, and therebymakes the juncture portions 28 durable. As a result, the parts 12 areable to be easily separated from the gates 16.

The resin molded body 10 has wide portions 30 at substantially centersof the non-connecting portions 26 connecting the gates 16 each other.The wide portions 30 make the weakest portions in the runners 16reinforced. Thus, during vibration is applied to the resin molded body10, the wide portions 30 prevent the runners 18 from being destroyedbefore the parts 12 are separated from the gates 16.

The resin molded body 10 has curve portions at the boundary portions 34between the wide portions 30 and the narrow width portions 32, whereinthe curve portions are gradually widened from the narrow width portions32 toward the wide portions 30. The curve portions make the strength ofthe boundary portions 34 further enhanced, and as a result, the parts 12can be easily separated from the gates 16.

Also, the resin molded body 10 has the thick portions 38 on the backfaces of the runners 18 between the connecting portions 25 and thenon-connecting portions 26, wherein the thick portions are thickened infront-to-back direction gradually from the non-connecting portions 26toward the connecting portions 25. The thick portions make theconnecting portions 25 between the gates 16 and the runners 18strengthened. As a result, the parts 12 are preferentially separatedfrom the gates 16 without separating between the gates 16 and therunners 18.

On the surfaces of the parts 12 of the resin molded body 10, charactersand symbols are formed by etching. The portion where the characters andsymbols are formed has transparency. When the cellular phone isassembled with the parts 12 for push button switch members and with alight source placed on the back side of the parts 12, light illuminatedfrom the light source transmits from the character formed portions andthe symbol formed portions of the push button switch members. As aresult, the characters and symbols can be visually recognized in a darkplace. Since the side faces of the part 12 are also coated, lightleakage is effectively prevented.

When the resin molded body 10 is arranged on the receiving jig 40, theelastic bodies 62 of the receiving jig 40 support the connectingportions 25 of the gates 16. When the resin molded body 10 is arrangedon the receiving jig 40, the gates 16 are supported by the elasticbodies 62 and by the elastic bodies 64, while the parts 12 are notcontacted with the receiving jig 40. Therefore, when vibration isapplied to the resin molded body 10, the vibration is effectivelytransmitted to the juncture portions between the gates 16 and the parts12. As a result, the parts 12 are easily separated from the gates 16.

In the method for manufacturing the push button switch member accordingto this embodiment, the resin molded body 10 is arranged on thereceiving jig 40, and vibration is applied from the back faces 16 b ofthe gates 16. Therefore, the back faces 12 b of the parts 12 are easilyseparated from the gates 16. As a result, working efficiency is improvedand the number of working processes and manufacturing costs are reduced.

Second Embodiment of the Present Invention

Hereinafter, a resin molded body 70 according to a second embodiment ofthe present invention will be described with referent to the drawings.In the following description about resin molded body 70 according to thesecond embodiment, some of common portions to the first embodiment aregiven the same numerals and the description of the common portions willbe omitted or simplified.

FIG. 11A shows a perspective view from the front side illustratingconfiguration of the resin molded body 70 according to the secondembodiment. FIG. 11B shows a perspective view from the back sideillustrating configuration of the resin molded body 70 according to thesecond embodiment. FIG. 12A shows an enlarged view of a portionsurrounded by a dashed-dotted line E in FIG. 11A. FIG. 12B shows anenlarged view of a portion surrounded by a dashed-dotted line F in FIG.11B.

As shown in FIGS. 11A and 11B, the resin molded body 70 mainly comprisestwelve parts 12, a frame 14, gates 72 and runners 74.

As shown in FIGS. 11A and 11B, the parts 12 are arranged inside of theframe 14 in four rows and three columns with specified intervals. On thefront surfaces 12 a of the twelve parts 12, numbers from “0” to “9” andsymbols of “*” and “#” are formed by etching or the like. The parts 12adjacent to the forward-and-rearward direction are connected by thegates 72. Six parts 12 arranged at the most forward row and the mostrearward row are connected to the frame 16 by the gates 72.

As shown in FIGS. 11B and 12B, the gate 72 has a substantiallyrectangular shape. At both forward and rearward ends on the back face ofthe gate 72, projections 76 projecting rearward are provided. As shownin FIGS. 11A and 11B, between the parts 12 adjacent to theforward-and-rearward direction, runners 74 connecting a left frameportion 14 e and a right frame portion 14 f each other are providedalong the right-and-left direction.

As shown in FIG. 12A, the runners 74 cross the gates 72 provided alongthe forward-and-rearward direction and are connected to the frontsurfaces 72 a of the gates 72. The connecting portions 78 of the runners74 and the gates 72 are wider in the forward-and-rearward direction thannon-connecting portions 80, wherein the non-connecting portions 80 arethe portions of the runners 74 where the runners 74 are not connected tothe gates 72 or to the frame 14 and where the runners 74 have the samewidth. At the juncture portions 81 of the runners 74 placed between theconnecting portions 78 and the non-connecting portions 80, gentle curveportions are formed. At the substantially central portions between theconnecting portions 78 and the non-connecting portions 80, wide portions82 are formed, wherein the wide portions 82 are wider in theforward-and-rearward direction than the non-connecting portions 80. Thewide portions 82 have substantially oval shape in a front view. On theback faces of the runners 74 between the connecting portions 78 and thenon-connecting portions 80, thick portions 83 are provided in order toreinforce the connecting portions 78.

Secondly, a receiving jig 86 used as a receiver when vibration isapplied to the resin molded body 70 to separate the parts 12 for thepush button switch member will be described.

FIG. 13 shows a perspective view illustrating configuration of thereceiving jig 86 according to the second embodiment.

As shown in FIG. 13, the receiving jig 86 has a cavity 88. The cavity 88comprises part fitting concave portions 89, a frame fitting concaveportion 90, and runner fitting concave portions 91 corresponding to theparts 12, the frame 14 and the runners 74 of the resin molded body 70,respectively.

The part fitting concave portions 89 are provided in four rows and threecolumns with specified intervals. The part fitting concave portions 89have substantially same shape as the shape of the parts 12. The framefitting concave portion 90 is provided in a square frame shapesurrounding the outside of the part fitting concave portions 89. Therunner fitting concave portions 91 are provided along the right-and-leftdirection between adjacent part fitting concave portions 89.

In the cavity 88, four wall bodies 92 are formed along theforward-and-rearward direction, which are separated by the runnerfitting concave portions 91. In each wall body 92, three part fittingconcave portions 89 are formed along the right-and-left direction. Thewall body 92 has a thin wall between the runner fitting concave portion91 and the part fitting concave portion 89 (hereinafter called “a sidewall 92 a”). On the runner fitting concave portions 91, elastic bodies93 are arranged from the left wall to the right wall of the wall bodies92. The elastic bodies 93 may be made from but not limited to resin suchas silicone rubber. The elastic bodies 93 have the same height as thewall bodies 92.

The method for manufacturing the resin molded body 70 and the pushbutton switch member in this embodiment is the same one as the method inthe first embodiment. Hereinafter, the different elements of the methodin this embodiment from the first embodiment will be described.

FIG. 14 is a view for explanation of the method for manufacturing thepush button switch member according to the second embodiment and shows across sectional view of the resin molded body 70 arranged on thereceiving jig 86. FIG. 15A shows a downward movement process in themethod for manufacturing the push button switch member according to thesecond embodiment. FIG. 15B shows a vibration process in the method formanufacturing the push button switch member according to the secondembodiment. FIG. 15C shows a state that the resin molded part 12 isseparating from the gate 72.

As shown in FIG. 14, the resin molded body 70 is arranged on thereceiving jig 86 with the back face being upside (arranging process:S104). In the arranged state, the resin molded body 70 is supported bythe elastic bodies 93, wherein the connecting portions 78 of the runners74 are in contact with the front faces 93 a of the elastic bodies 93,and wherein the parts 12 are not in contact with a front face 88 a ofthe cavity 88.

Then, as shown in FIG. 15A, a horn 68 of an ultrasonic vibrator isbrought down from the upside (the back side) of the resin molded body 70arranged on the receiving jig 86 (downward movement process: S105). Asthe horn 68 is brought down, an end face 69 a of each projection 69contacts to the back face 76 b of the projection 76. And then, the horn68 is pressed onto the projection 76, and the connecting portion 78 isslightly pushed into the elastic body 93 (the pushed-in state is notshown in any figures). After that, the ultrasonic vibration is appliedto the gate 72 (vibrating process: S106). Then, as shown in FIG. 15C,the parts 12 are separated from the gates 72. The separated parts 12 aregrasped by a machine or a person and aligned at predetermined positionsin a predetermined assembling jig (aligning process: S107).

Since the connecting portions 78 of the resin molded body 70 formed bythe above method are wider than the non-connecting portions 80, theconnections between the gates 72 and the runners 74 are strengthened.Therefore, the parts 12 preferentially separate from the gates 72.Additionally, each runner 74 of the resin molded body 70 has a wideportion 82 at substantially center of the non-connecting portion 80connecting to the gate 72. The wide portion 82 makes the weakest portionin the runner 16 reinforced. Thus, during vibration is applied to theresin molded body 70, the wide portions 82 prevent the runners 74 frombeing destroyed before the parts 12 are separated from the gates 72.

Also, the resin molded body 70 has the thick portion 83 on the back faceof the runner 74 between the connecting portion 78 and thenon-connecting portion 80, wherein the thick portion 83 is thickened infront-to-back direction. The thick portion 83 makes the connectingportion 78 strengthened. As a result, the parts 12 are preferentiallyseparated from the gates 72 before the gates 72 separate from therunners 74.

When the resin molded body 70 is arranged on the receiving jig 86, theelastic bodies 93 of the receiving jig 86 support the connectingportions 78 of the gates 72. When the resin molded body 70 is pressedonto the receiving jig 86, the gates 72 are supported by the elasticbodies 93 and by the side wall 92 a, while the parts 12 are notcontacted with the receiving jig 86. Therefore, when vibration isapplied to the resin molded body 70, the vibration is effectivelytransmitted to the gates 72, and the runners 74 are prevented from largevibration. As a result, the parts 12 are easily separated from the gates73.

The present invention is not limited to the above-mentioned firstembodiment and second embodiment but is able to be put into practice invariations.

In the above-mentioned embodiments, twelve parts 12 in total areprovided in the resin molded bodies 10, 70, respectively. But, thenumber of the parts may be more than 13 or less than 11.

In the above-mentioned embodiments, the runners 18, 74 are provided onlyin the right-and-left direction, but the runners may be provided in theforward-and-rearward direction or in both of the forward-and-rearwarddirection and right-and-left direction. In these cases, the receivingjigs should be designed to correspond to the runners.

In the above-mentioned embodiments, the shape of the part 12 is arectangular flat plate, but the shape is not limited to above-mentionedshape, and may be a flat plate having another shape such as a hexagon ora circle.

In the above-mentioned embodiments, a plurality of projections 69 areprovided in the horn 68, but the end face of the horn 68 opposing to theresin molded body may be a flat face without any projections.

In the above-mentioned embodiments of the resin molded bodies 10, 70,the parts 12 are arranged inside the frame 14 in four rows and threecolumns with a specified interval, but a placement of parts is notlimited to that, and may be arranged in other layout such as five rowsand three columns or the like. Also, other members but the parts 12which are key tops for a push button switch member may be arrangedinside the frame 12.

In the above-mentioned embodiments, the front face 62 a of the elasticbody 62 and the front face 93 a of the elastic body 93 have a planarshape, respectively, but a shape of the front faces is not limited toabove-mentioned shape. For example, as shown in FIGS. 16A and 16B, thefront face 62 a may have a concave portion 95 to which the connectingportion 25 is fitted and the front face 93 a may have a concave portion96 to which the connecting portion 78 is fitting.

In the above-mentioned embodiments, when the resin molded bodies 10, 70are arranged on the receiving jig 40, 86, respectively. The connectingportions 25, 78 are supported by the elastic bodies 62, 93,respectively. But, a formation for an arrangement of a resin molded bodyand a receiving jig is not limited to that. For example, the elasticbodies 62, 93 may support the non-connecting portions 26, 80,respectively in the above embodiments. Also, an elastic body may beprovided in a frame fitting concave portion such as the frame fittingconcave portion 46 or the frame fitting concave portion 90 so that theelastic body supports the frame 14.

In the above-mentioned first embodiment, any projecting portions are notprovided on the front face of the elastic body 10 at the connectingportion 25 and at the wide portion 30. But, as shown in FIG. 17, aprojecting portion such as a projecting portion 97 a and/or a projectingportion 97 b may be provided on a front face of the elastic body at aconnecting portion such as the connecting portion 25 and/or at a wideportion such as the wide portion 30, wherein the projecting portionprotrude from back-to-front direction. In this case, as shown in FIG.18, the receiving jig 40 preferably has a circular concave portion suchas a circular concave portion 98 and/or a groove portion such as agroove portion 99 at positions corresponding to the projecting portionssuch as the projecting portion 97 a and/or the projecting portion 97 bof the resin molded body, respectively. The circular concave portion 98is formed between two indented portions 57 to be indented toward backface in the elastic body 92. The groove portion 99 is formed over thegate fitting concave portion 48 to be indented toward back face in theelastic body 62. In an arrangement of the resin molded body 10 on thereceiving jig 40, as shown in FIG. 19, the projecting portion 97 a orthe projecting portion 97 b is fitted in the groove portion 99 or thecircular concave portion 98 through a clearance 100 a or a clearance 100b, respectively.

In the above first embodiment, all shapes of the runners 18 are thesame. But, as shown in FIG. 20, a reinforcing portion 101 may beprovided on the back face of the runner 18. The reinforcing portion 101has a larger dimension in cross-section vertical to the right-and-leftdirection than the dimension of the runner 18.

The resin molded body of the present invention can be used for a pushbutton switch member of various electric equipments.

The present invention has been described in the context of a number ofembodiments and variations thereof. It is, however, appreciated thatother expedients known to those skilled in the art may be employedwithout departing from the spirit of the invention. Therefore, it isintended that the appended claims be interpreted as including theembodiments described herein, the alternatives mentioned above, and allequivalents thereto.

1. A receiving jig for separating resin molded parts from a resin moldedbody by applying ultrasonic vibration in a condition that the resinmolded body is interposed between the receiving jig and a horn, theresin molded body comprising: (a) one or more resin molded parts for thepush button switch member, (b) a frame surrounding the outside of theresin molded parts, (c) one or more gates connecting a plurality of theresin molded parts to each other or to the frame and (d) one or morerunners crossing the longitudinal direction of the gates, wherein thegates are connected at the back faces of the resin molded parts, andwherein the runners are connected to the gates on the same surfaces asthe resin molded parts are connected to the gates and are connecting theopposing sides of the frame to each other; and the receiving jigincluding a cavity on the surface where the resin molded body isreceived and one or more projecting portions project from the bottomsurface of the cavity, wherein the projecting portions support from thefront faces of the resin molded parts at least one of following (1) aplurality of ends of the gates being connected at the back faces of theresin molded parts not to be painted with light shielding paint, and thegates connecting a plurality of resin molded parts to each other or thegates connecting between the frame surrounding the outside of the resinmolded parts and the resin molded parts, (2) one or more runnerscrossing the longitudinal direction of the gates, the runners beingconnected to the gates on the same side of the surface where the resinmolded parts are connected to the gates and the runners connecting theopposing sides of the frame to each other and (3) the frame, whereinpart fitting concave portions are provided in the area where theprojecting portions are not provided in the cavity, and the part fittingconcave portions are provided so as to be opposite to the resin moldedparts without contacting, wherein one or more concave portions areformed at the projecting portions so as to be depressed toward thebottom surface of the cavity at a position opposite to at least one ofthe gates, the runners and the frame, and wherein one or more elasticbodies, which make a larger impact on the gates than other parts of theresin bolded body by deformation when applying the ultrasonic vibrationto the gates, are filled in at least a position opposite to the gates inthe concave portions.